box of mixed Hydraulic cylinder seals reseal resealing for heavy equipment earthmoving mining quarries.

The 5 Hydraulic Cylinder Resealing Must-Knows

Your hydraulic cylinder resealing process has already begun. You’ve disassembled it and you have a bag (or box) of brand-new seals. Now you want to get the new seals in and the hydraulic cylinder assembled and back on the machine. But you want to do it right the first time. And this is good. Because the last thing you need is to do all this work and the hydraulic cylinder starts leaking again. Because there are a few points that you should know when doing a reseal. Well, there are five points that are important to know. By considering these, you can further improve the reliability and restore performance of your hydraulic cylinder after resealing. Also, we’ll assume the seals you’re supplied with are suitable for the machine and its hydraulic fluid. #1 Inspect Start by inspecting the hydraulic cylinder itself. Look at the condition of the bore and rod for wear, scoring, or damage. Repair or replace any damaged parts. Installing new seals won’t make up for damaged parts. #2 Quality You’re going to inspect the seals and make sure what’s supplied are the correct seals. On top of this, check the condition of each item. Seals may appear new at a glance. Look closer… Are they at a standard or condition to what you’re satisfied with?  If not, get it replaced. #3 Technique An insider secret to installation technique is to avoid forcing the seals and causing them to kink into sharp bends. If you’re finding it difficult to install a seal in an internal groove then use dedicated seal installation tooling to assist. For external seals, such as those for the piston, only expand the seal enough to slip over the component body. Over-stretching can permanently damage the seal and reduce its life. #4 O-Ring After you’ve installed an O-ring, check that it’s not sitting twisted. Having a twisted hydraulic O-ring compromises the sealing performance and life. Majority of times O-rings are installed manually, so use tools without sharp edges. #5 Lubricant There’s a huge range of lubricants and greases, but not all are compatible with your seals. Lubes that have solid additives, such as molybdenum disulphide should be avoided. It may be suitable for pins and bushes, rod ends, and CV joints, but not for hydraulic cylinder seals. A compatible and readily available medium for lube is the machine’s hydraulic oil. You can use hydraulic oil to lube the seal that need to be stretched slightly as it is being located into the groove, such as a piston seal. Lubricate the barrel bore with a film of hydraulic oil before assembly. How To Get Hydraulic Cylinder Help Resealing a hydraulic cylinder can end up a time-consuming task that requires expertise and special processes, especially within the demanding environment of the mining, and earthmoving industry. While understanding the key steps can help, handling this work in-house may not be the most efficient use of your resources. By entrusting this job to our expert team, you can save valuable time and money, gain peace of mind, and benefit from our professional warranty. We specialise in servicing hydraulic cylinders for the mining, earthmoving, and heavy equipment industries, ensuring your equipment operates at peak performance with minimal downtime. Contact us today to have your hydraulic cylinders serviced by our expert team, allowing you to focus on maximising productivity and efficiency in your operations. Contact us on 07 3800 8721 and a friendly team member will help you get the best solution for you. Contact us today Written by The A1HE Team Date: 05.07.2024

A bent rod from a hydraulic cylinder repaired by A1 Hydraulic Engineering reman rod re-rod

Top 4 Reasons Hydraulic Cylinder Rods Bend

A major failure for hydraulic cylinders is when the rod bends or buckles when in operation. Usually when a rod is bent it also damages the gland, and at times, the piston and bore too. Pretty much have the hydraulic cylinder to catastrophically fail. Why can the other parts fail? A hydraulic cylinder has specific engineered tolerances and clearances. The rod, gland, piston, and barrel bore are all ‘straight’ to each other. So when a rod has a bend in it, it’s centre axis is no longer inline or straight with the other component. This puts excessive loads to guide rings and bushes. The piston becomes ‘crooked’ and the gland gets damaged as it becomes a fulcrum for the bend. Retracting a bent rod into the cylinder does not straighten it again. The machine should be immediately stopped and the failed hydraulic cylinder repaired or replaced. So here they are… Top 4 Reasons Why Hydraulic Cylinder Rods Bend Rod diameter too small Inadequate rod material strength Improper cylinder mounting arrangement Machine misuse/abuse by the operator What You Can Do About It If there are loads greater than the rods ability to withstand bending or buckling, then a new rod should be manufactured with an increased diameter and/or higher material strength. For reason No.4, it just comes down to operator training and care for the machine or attachment. If they are being used outside the manufacturer’s original design and operational intent then don’t be surprised if the hydraulic cylinders fail and the overall machine uptime and life is drastically reduced. How to spot a possible bend in a rod Here are some way you can spot a possible bend in a hydraulic cylinder rod: ‘Juddering’ during operation An audible sound during operation Oil leakage from seals Rod scoring Irregular rod wear patten What You Need To Do If you suspect that your hydraulic cylinder has a bend or needs attention, contact us today. Getting the cylinder looked at now is far better than putting it off and having catastrophic failure. Contact us now on 07 3800 8721 and a friendly team member will help you get the best solution. Contact us today Written by The A1HE Team Date: 26.04.2024

hydraulic cylinder on an earthmoving machine excavator that may have dieseling which can damage hydraulic seals and piston so you need to contact A1 hydraulic engineering to reseal, reman, remanufacture, manufacture hydraulic cylinders

5 Steps To Remove Air Form Hydraulic Cylinders

Whenever you are installing a hydraulic cylinder to your machine, you should always assume that some air will be introduced in the hydraulic system. You can lose oil during the process of disconnecting and reconnecting hoses, fittings, burst/craning valves, or even when installing hydraulic cylinder that’s completely empty. All these situations are not a problem when you understand what dieseling is. What’s dieseling? Simply put it’s the detonation of trapped air in oil when compressed. Just think about how a diesel engine works. Dieseling can damage pistons and the seals. Shortening the life of the hydraulic cylinder. It also means it reduces machine uptime. That’s why it best practice to bleed or remove air after any hydraulic cylinder service, when getting a new cylinder, or when there’s a possibility of air that’s entered into the hydraulic cylinders, Before You Start Check the machine’s maintenance manual for the procedure that’s specific or recommended for you. The below procedure is general guideline. You need to keep the machines’ engine at a low RPM/idle throughout the whole procedure. And be patient. Don’t rush this important process. Don’t run the engine at full noise and sudden control movements to fill the hydraulic cylinder quicker. You are only promoting for dieseling to occur. The 5 Steps Keep the engine at low idle and then… Step 1: For 8 cycles, slowly extended and retracted the cylinder through approximately 3/4 of the full cylinder travel. Do this for 8 to 10 cycles. Don’t let the cylinders reach the stroke ends (bottom out), in both directions. Step 2: Pause before you change direction for a minimum of 5 seconds. Step 3: Then, slowly cycle the hydraulic cylinders to the full extend and retract travel, while keeping the hydraulic pressure low. Step 4: Pause before you change direction for a minimum of 5 seconds. Step 5: Finally, check the hydraulic oil level and top up as needed. Getting Your Hydraulic Cylinder Serviced If your machines’ hydraulic cylinders are leaking, loosing efficiency, or if you suspect that dieseling has occurred… Contact us now on 07 3800 8721 and a friendly team member will help you get the best solution. Contact us today Written by The A1HE Team Date: 14.03.2024

hydraulic cylinders on an Excavator with grab attachment that A1 Hydraulic Engineering does service and repair and manufacture reman remanufacturing in earthmoving mining quarry civil and industrial

Ground-Breaking Power Source For Hydraulic Cylinders

Big changes are happening in the earthmoving industry. This isn’t just a shift in fuel preferences; it’s a new way to make equipment cleaner and more sustainable, significantly altering how we power our heavy machinery. Major brands are already taking the lead, experimenting with hydrogen fuel cells and hydrogen-electric systems to bring about a greener era. To top it off, a brilliant team in the University Of NSW have patented a Hydrogen-Diesel Direct Injection Duel-Fuel System. This can make existing diesel engines use 90% hydrogen and have an 85% CO2 emission reduction! But here’s the twist – it’s not just about flashy new designs. A few industry giants are also revamping existing diesel-powered machines into hydrogen-electric powerhouses, trying out hydrogen-power on equipment. So Why All The Fuss? Unlike the traditional diesel and natural gas options, hydrogen is gaining popularity as a cleaner alternative. While electric machinery has been around, it’s not always the perfect fit for every job. Hydrogen steps in as a versatile option, delivering no emissions while maintaining the power, torque, and response time we’re used to with regular combustion engines. Here’s the amazing part – you don’t necessarily need an entirely new fleet to jump on the hydrogen bandwagon. Heavy machinery vehicles are being converted from diesel power to hydrogen-electric, showing that owners and managers can make a sustainable upgrade without a hefty price tag of an entire new fleet. And with the hydrogen market on the rise, earthmoving companies will have more options, from getting new equipment to tapping into the expanding hydrogen infrastructure. It’s not just about adopting a new method; it’s about reshaping how we look at progress in the heavy machinery industry. However, Here’s What You Should Know All these machines will still need to be serviced and maintained, including their hydraulic cylinders. Keeping your earthmoving machine’s hydraulic cylinders in top condition is vital to get the best efficiency and uptime. If your machine’s hydraulic cylinders are leaking, loosing power, or damaged, then don’t leave it any longer. For all your hydraulic cylinder enquiries and servicing call us on 07 3800 8721 and a friendly team member will help you get the best solution. Contact us today Written by The A1HE Team Date: 4.12.2023

An earthmoving machine cat caterpillar yellow grader in the minimg and earthmoving industry that A1 Hydraulic Engineering service and reseal and manufacture and reman and remanufacture hydraulic cylinders with electronic monitoring and service system

Will This Earthmoving Trend Take Off?

Ever wondered how you could enhance your machine’s performance and streamline your operations? Well, here’s the trend that’s growing with earthmoving machine manufacturers:  Electronic Machine Monitoring. In a nutshell, electronic monitoring allows you to keep a close eye on your machines in real time. You can use this technology the right way and change the way you operate, forever.  Or, will it end up like the app on your phone that’s rarely used but you know it does more stuff?    Imagine having the power to monitor fuel efficiency, track usage patterns, and even receive maintenance alerts, conveniently sent to your office or smartphone. It’s like having your own personal assistant. Now, you might be wondering, “Why should I look into machines with electronic monitoring?”  Game-Changer For Earthmoving Here’s why it can be a game-changer for earthmoving companies just like yours:  1. Earthmoving Efficiency: Know exactly how your machines are performing on the field. Find out the areas where you can better improve productivity, including the selection of attachment over another machine. 2. Maintenance Management: Never miss a beat by getting instant alerts about needed maintenance. Stay ahead of potential issues, minimise downtime and eliminate machine neglect.  3. Cost Efficiency: Monitor fuel usage and machine productivity. Get the extra help to cut down on operational costs and increase your overall profitability. 4. Safety Mindset : Monitor operator behavior and how the machine is treated. Build a safe working environment for your company.  5. Information In Real Time: Get all the data you need in real time. Manage your machines with ease. Improve your job site decision making. What It Means For You  At A1 Hydraulic Engineering, we understand the challenges faced by earthmoving companies. Whether you have an electronic monitoring feature in your machines or not, proper machine care should be your priority.  And the hydraulic cylinders are no exception. When your machine’s hydraulic cylinders are it top condition then your not going to get the unnecessary loss of energy that happens by decreasing efficiency. And with rising energy costs, having a mind set for machine care is as great company culture trait.   For all your hydraulic cylinder enquiries and servicing call us on 07 3800 8721 and a friendly team member will help you get the the best solution. Contact us today Written by The A1HE Team Date: 27.10.2023

resealing seals of various sizes and colours showing that A1 Hydraulic Engineering Hydraulic Cylinder Reseals Hydraulic Cylinder Repairs Hydraulic Cylinder Manufacturing

What You Should Know About Hydraulic Cylinder Seals

Hydraulic cylinder seals deteriorate over time due to many factors, and knowing the most common reasons behind this deterioration is vital for maintaining the performance and longevity of any hydraulic cylinder and the hydraulic system to your machine. Factors that contribute to seal deterioration include: environmental conditions, pressures, temperature exposure, and sealing materials. When a hydraulic cylinder is showing first signs of seal deterioration, such as leaks and loss of efficiency, then the best thing is to start planning to have it resealed. It is not uncommon for operators to ‘push’ the machine further and to work it longer – and even ignoring any signs altogether! Ways Hydraulic seals can deteriorate and fail 1. Extrusion: This occurs when high pressure forces the seal material to deform or extrude into gaps or clearances in the cylinder, compromising its integrity and sealing performance. 2. Compression Set: Over time, seals may lose their ability to return to their original shape after being compressed, ending up permanently deformed and loss of effectiveness. 3. Hardening and Cracking: Exposure to heat or extreme temperature, chemicals, or UV exposure can cause the seals to harden and become brittle, eventually leading to cracking or breakage. 4. Swelling: Some hydraulic fluids may cause seals to swell or expand, affecting its housing fit and sealing ability. 5. Contamination: Normal wear from repetitive motion is accelerated when contaminants, such as dust or abrasive particles, enter the hydraulic system and come into contact with the seals. When a hydraulic cylinder is showing first signs of seal deterioration, such as leaks and loss of efficiency, then the best thing is to start planning to have it resealed. Why You Shouldn’t Neglect These Signs Taking lightly any signs of hydraulic cylinder seal deterioration can have serious consequences. When seals start to deteriorate, they aren’t doing what their functions are for: sealing, guiding, wiping, and protecting. Leaking and bypassing seals leads to poor efficiency and the high risk of damage to the hydraulic system. The final result of neglect can be an expensive catastrophic failure to the hydraulic cylinder and system.   The best solution for hydraulic cylinder seal deterioration is to get it serviced. Inspect seals often for signs of leakage or damage. Seals must be replaced at the first sign of deterioration to prevent more problems. Use only high-quality seals that’s specific for the hydraulic system and following proper maintenance and operating practices, such as keeping hydraulic fluid clean and within recommended temperature and pressure limits, can help extend the life of seals.   What To Do Next For all your hydraulic cylinder enquiries and servicing call us on 07 3800 8721 and a friendly team member will help you get the the best solution. Contact us today Written by The A1HE Team Date: 5.10.2023